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TRANSCRIPT
OPERATING INSTRUCTIONS
ESE 604 DBG DIN Article No. 151002
ESE 604 DBG ES DIN Article No. 151012
ESE 604 DBG ES FS DIN Article No. 151022
ESE 954 DBG DIN Article No. 151004
ESE 954 DBG ES DIN Article No. 151014
ESE 954 DBG ES FS DIN Article No. 151024
2 ESE 604 / 954 DBG DIN Status at: January 2013
ENDRESS Elektrogerätebau GmbH Neckartenzlinger Str. 39
D-72658 Bempflingen
Telephone: + 49 (0) 71 23 / 9737 – 0 Telefax: + 49 (0) 71 23 / 9737 – 50 Email: [email protected] www: http://www.endress-stromerzeuger.de
E132569
January 2013
© 2013, ENDRESS Elektrogerätebau GmbH
This documentation and parts thereof are subject to copy-right. Any use or modification beyond the restrictions of the Copyright Act is forbidden and subject to penalty without the consent of ENDRESS Elektrogerätebau GmbH.
This applies in particular to copies, translations, microfilming, as well as storage and processing in electronic systems.
Manufacturer and publisher
Document number
Publication date
Copyright
Table of Contents
Status at: January 2013 ESE 604 / 954 DBG DIN 3
Table of Contents
Operating Instructions .............................................................................................. 1
ENDRESS ................................................................................................................... 2
Elektrogerätebau GmbH ............................................................................................ 2
E132569 ...................................................................................................................... 2
1 General information .......................................................................................... 9
1.1 Further documents ........................................................................................... 10
1.2 Used signs and symbols .................................................................................. 11
1.2.1 General signs / symbols .....................................................................................11
Advanced Organizer ................................................................................................ 11
Note 11
1.2.2 Safety symbols ...................................................................................................12
General hazard warning .......................................................................................... 12
Potentially explosive materials .............................................................................. 12
Dangerous electrical voltage .................................................................................. 12
Poisonous substances ............................................................................................ 12
Environmentally damaging substances ................................................................ 12
Hot surfaces ............................................................................................................. 12
Notes......................................................................................................................... 13
2 General Safety Regulations............................................................................ 14
2.1 Important safety warning .................................................................................. 14
2.1.1 Intended use .......................................................................................................15
2.1.2 Foreseeable incorrect use or inappropriate handling .........................................16
Table of Contents
4 ESE 604 / 954 DBG DIN Status at: January 2013
2.1.3 Residual risks .....................................................................................................17
2.2 Operating personnel – qualifications and obligations ....................................... 19
2.3 Personal protective equipment ......................................................................... 19
2.4 Danger zones and work areas ......................................................................... 20
2.5 Signs on the generator ..................................................................................... 21
2.6 General safety instructions ............................................................................... 23
Notes......................................................................................................................... 27
3 Description of the ESE 604 / 954 DBG DIN generator .................................. 28
3.1 Components of the ESE 604 / 954 DBG DIN generator ................................... 28
3.1.1 Components of the operating and generator side ..............................................29
3.1.2 Exhaust and engine side components ...............................................................30
3.1.3 Control panel components ..................................................................................31
3.1.4 Accessory components ......................................................................................32
3.2 Function and mode of operation ....................................................................... 33
Notes......................................................................................................................... 34
4 Operating the ESE 604 / 954 DBG DIN generator ......................................... 35
4.1 Transporting the generator ............................................................................... 35
4.2 Setting up the generator................................................................................... 35
Set up the generator as follows: ............................................................................ 36
4.3 Refuelling the generator ................................................................................... 36
Refuel the generator as follows: ............................................................................ 37
4.4 Starting the generator ...................................................................................... 37
Start the engine as follows: .................................................................................... 38
4.5 Switching the generator off .............................................................................. 41
The device is switched off as follows: ................................................................... 41
4.6 Connecting up to consumers ........................................................................... 42
Switch the consumer on as follows: ...................................................................... 42
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Status at: January 2013 ESE 604 / 954 DBG DIN 5
Switch the consumer off as follows:...................................................................... 43
Disconnect a consumer from the control panel as follows: ................................ 43
4.7 Check the protective conductor (valid for devices up to year of construction 12/2015) .......................................................................................................... 44
4.8 Monitoring the operating status using the multifunction display ........................ 46
4.9 Putting the generator out of service ................................................................. 49
4.10 Disposal ........................................................................................................... 49
Notes......................................................................................................................... 50
5 Special fittings / using accessories ............................................................... 51
5.1 FI protection switch .......................................................................................... 51
5.2 Insulation monitoring using E-MCS 4.0 ............................................................ 53
5.2.1 Insulation monitoring without switching off .........................................................53
5.2.2 Insulation monitoring with switch off ...................................................................54
5.3 Speed lowering in idle ...................................................................................... 56
Switch on idle speed reduction as follows: .......................................................... 56
Switch the idle down off as follows: ...................................................................... 56
5.4 Remote start device ......................................................................................... 57
Connect up the remote start device as follows: ................................................... 57
Disconnect the remote start device as follows: .................................................... 58
Start the engine manually as follows: .................................................................... 58
The device is switched off as follows: ................................................................... 59
5.5 External start device ........................................................................................ 60
Connect up the external start device as follows: ................................................. 60
Disconnect the external start device as follows: .................................................. 60
5.6 Battery charge retention ................................................................................... 61
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6 ESE 604 / 954 DBG DIN Status at: January 2013
Disconnect the battery charge conservation device as follows: ........................ 61
Disconnect the battery charge conservation device as follows: ........................ 62
Disconnect the battery charge conservation device as follows: ........................ 63
5.7 3-way fuel valve / Refuelling device ................................................................. 64
Connect up fuelling device as follows: .................................................................. 65
Connect the canister to the fuelling device as follows: ....................................... 66
5.8 Exhaust hose ................................................................................................... 67
Connect up the exhaust hose as follows: ............................................................. 67
Disconnect the exhaust hose from the generator by: .......................................... 68
6 Servicing and maintaining the ESE 604 / 854 DBG DIN generator .............. 69
6.1 Maintenance plan............................................................................................. 69
6.2 Maintenance work ............................................................................................ 70
6.2.1 Motor oil ..............................................................................................................70
Check the oil level as follows: ................................................................................ 71
Pour in oil as follows: .............................................................................................. 71
6.2.2 Replacing the starter battery ..............................................................................73
6.2.3 Replacing fuses ..................................................................................................74
6.3 Checking the electrical safety .......................................................................... 75
7 Troubleshooting .............................................................................................. 76
Notes......................................................................................................................... 79
8 Technical specifications ................................................................................. 80
Notes......................................................................................................................... 83
9 Replacement parts .......................................................................................... 84
9.1 Frame with covers, tank and engine ................................................................ 84
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Status at: January 2013 ESE 604 / 954 DBG DIN 7
9.2 Generator and electronics ................................................................................ 87
9.3 Fuses ............................................................................................................... 89
9.4 Accessories and markings ............................................................................... 90
List of illustrations
Figure 2-1: Signs on the generator .....................................21 Fig. 3-1: Views of the generator ..........................................28 Fig. 3-2: Components of the operating and generator side .29 Figure 3-3: Exhaust and engine side components ..............30 Fig. 3-4: Control panel components ....................................31 Figure 3-5: Components of the standard accessories .........32 Fig. 3-6: Components of the special accessories ................33 Figure 4-1: Started by hand: ...............................................39 Figure 4-2: Electrical start ...................................................40 Fig. 4-3: Connecting up to consumers ................................42 Figure 4-4: Check the protective conductor ........................44 Figure 4-5: Multi-functional display .....................................46 Figure 5-1: FI protection switch ..........................................52 Figure 5-2: Insulation monitoring using E-MCS 3.0 .............53 Figure 5-3: Switching the idle down on pressure switch ......56 Figure 5-4: Connecting up a remote start device ................57 Figure 5-5: Electrical start in combination with remote start 58 Figure 5-6: Connecting up an external start device .............60 Figure 5-7: Connecting up the battery charge retention
device ..........................................................................61 Fig. 5-8: Connecting up the battery charge retention device
....................................................................................62 Fig. 5-9: Connecting up the battery charge retention device
....................................................................................63 Figure 5-10: 3-way fuel valve ..............................................64 Figure 5-11: Connect up fuelling device .............................65 Fig. 5-12 Connecting the exhaust hose ..............................67 Figure 6-1: Oil dipstick ........................................................70 Figure 6-2: Changing the oil ...............................................71 Figure 6-3: Replacing the battery .......................................73 Fig. 6-4: Replacing a fuse ...................................................74 Fig. 8-1: Generator dimensions ..........................................80 Figure 9-1: Operating and alternator side replacement parts
....................................................................................84 Fig. 9-2: Engine and exhaust side replacement parts .........85 Fig. 9-3: Replacement parts Generator and electronics ......87 Figure 9-4: Replacement parts for fuses .............................89 Fig. 9-5: Replacement parts accessories ............................90 Fig. 9-6: Replacement parts forspecial accessories ............91
Table of Contents
8 ESE 604 / 954 DBG DIN Status at: January 2013
List of tables
Table 2.1: Danger zones and work areas on the generator 20 Table 2.2: Signs on the generator.......................................22 Table 4.1: Protective conductor test lamp ...........................45 Table 5.1: FI protection switch test .....................................52 Table 5.2: Insulation monitoring without switching off .........53 Table 5.3: Insulation monitoring whilst running without
switching off ................................................................54 Table 5.4: Insulation monitoring plus switching off ..............55 Table 5.5: Insulation monitoring whilst running without
switching off ................................................................55 Table 5.6: Switchingpositions of the 3-way fuel tap ............64 Table 6.1: Generator maintenance plan .............................69 Table 6.2: Location of the fuses .........................................74 Table 7.1: Problems arising during generator operation .....78 Table 8.1: Generator technical data ....................................81 Table 8.2: Ambient conditions for the generator .................82 Table 8.3: Generator power reduction dependent on ambient
conditions ....................................................................82 Table 8.4: Maximum line length of the distribution network as
a function of the cable cross-section............................82 Table 9.1: Replacement parts for covers ............................86 Table 9.2: Replacement parts for an engine with an exhaust
and fuel system ...........................................................88 Table 9.3: Replacement parts for fuses ..............................89 Table 9.4: Replacement parts for accessories / special
accessories .................................................................91
General note: The illustrations in these operating instructions do not always
comply completely with the actual design, in particular with regard to the colour, and are to be considered a representa-tion of basic principles.
We reserve the right to make modifications in terms of ongoing technical development.
These instructions do not include technical modifications that occurred after printing.
General information
Status at: January 2013 ESE 604 / 954 DBG DIN 9
1 General information
These operating instructions must be read carefully and un-derstood before using the generator.
These operating instructions are intended to familiarise you with the basic operation of the generator.
These operating instructions contain important information on using the generator safely and appropriately.
Complying with this information helps to:
avoid hazards
reduce repair costs and downtime
increase the reliability and service life of the generator.
However, not only these operating instructions but also the laws, regulations, guidelines, and standards applicable in the country of use and at the site of operation must be observed.
These operating instructions only describe the generator operation.
A copy of these operating instructions must be available to the operating personnel at all times.
General information
10 ESE 604 / 954 DBG DIN Status at: January 2013
1.1 Further documents
In addition to these operating instructions, the following doc-uments are relevant for the generator:
Operating instructions and maintenance instructions for the engine (Briggs & Stratton Corporation)
Briggs & Stratton Service Germany (Briggs & Stratton Corporation)
Circuit diagram for the generator
Test protocol for the power generator
Regulations for handling the battery
The operating manual and the maintenance instructions from the engine manufacturer are integral components of these instructions and must be observed.
General information
Status at: January 2013 ESE 604 / 954 DBG DIN 11
1.2 Used signs and symbols
The signs and symbols in these operating instructions help you to use the operating instructions and the device quickly and safely.
1.2.1 General signs / symbols
Advanced Organizer
The Advanced Organizer informs you briefly about the con-tents of the following chapter.
Note
The reference note informs you about the most effective and/or most practicable way to use the equipment and these operating instructions.
1. Operating steps
2. …
3. The defined sequence of the operating steps facilitates correct and safe use of the equipment.
Result
The result of a sequence of operating steps is described here.
NOTE
General information
12 ESE 604 / 954 DBG DIN Status at: January 2013
1.2.2 Safety symbols
The safety warning symbol indicates that a source of danger exists. The safety warning symbols used in the work area of the machine/plant and the entire technical documentation correspond to the Council Directive 92/58/EEC - Minimum requirements for the provision of safety and/or health signs at work.
General hazard warning
This warning symbol indicates activities where several caus-es can lead to risks.
Potentially explosive materials
This warning symbol indicates activities during which there is an explosive hazard, possibly with lethal consequences.
Dangerous electrical voltage
This warning symbol indicates activities during which there is the danger of an electric shock, possibly with lethal conse-quences.
Poisonous substances
This warning symbol indicates activities during which there is the danger of poisoning, possibly with lethal consequences.
Environmentally damaging substances
This warning sign indicates activities during which the envi-ronment could be endangered, possibly with catastrophic consequences.
Hot surfaces
This warning symbol indicates activities during which there is the danger of burns, possibly with lasting consequences.
General information
Status at: January 2013 ESE 604 / 954 DBG DIN 13
Notes
14 ESE 604 / 954 DBG DIN Status at: January 2013
2 General Safety Regulations
This section describes the basic safety regulations for oper-ating the generator.
Whoever operates the generator or works with it must read this chapter and comply with its regulations in practice.
2.1 Important safety warning
ENDRESS generators are designed to operate electrical equipment with appropriate power output requirements. Oth-er applications can lead to injury to the operating personnel and to damage to the generator as well as other damage to equipment.
The majority of injuries and damage to equipment can be avoided if all instructions given in this manual and all instruc-tions attached to the generator are followed.
The generator must not be modified in any way. This can lead to an accident occurring and damage to the generator as well as devices.
WARNING!
Status at: January 2013 ESE 604 / 954 DBG DIN 15
The following actions are not permitted.
Operation in explosion-prone environments
Operation in fire-prone environments
Operation in confined areas
Operation from a vehicle platform that has not been swung out
Operation without the necessary safety redundancies
Operation in existing power supply networks
Refuelling when hot
Refuelling during operation
Spraying with high-pressure cleaners or fire-extinguishing equipment
Safety equipment removal
Incorrect vehicle installation
Non-compliance with maintenance intervals
Failure to measure and test for early damage identifica-tion
Failure to replace wearing parts
Incorrectly performed maintenance or repair work
Defectively performed maintenance or repair work
Unintended use
2.1.1 Intended use
The generator produces electricity in place of the power grid, in order to supply a mobile distribution system.
The generator is only to be used outdoors within the indicat-ed voltage, output, and nominal rpm ranges (see name-plate).
You are also permitted to use it on a vehicle extension or swivelling platform in both extended and swung out states, providing that the air circulation is uninterrupted on all sides of the generator and that the exhaust gases are dispersed correctly. This is especially relevant as access to the side with the instrument panel and the side with the exhaust gas connection must be unrestricted.
The methods that will be used to install the generator on these vehicle platforms require written approval from the distributor that supplied the generator.
16 ESE 604 / 954 DBG DIN Status at: January 2013
The generator is not to be connected up to other energy dis-tribution systems (e.g. public power supply) or to other ener-gy generation systems (e.g. other generators).
The generator is not to be used in explosion-prone environ-ments.
The generator is not to be used in fire-prone environments.
The generator must be operated according to the specifica-tions in the technical documentation.
Every inappropriate use or all activities on the generator which are not described in these instructions are forbidden misuse outside the legally defined limits of liability of the manufacturer.
2.1.2 Foreseeable incorrect use or inappropriate handling
Foreseeable incorrect use or inappropriate handling of the generator nullifies the manufacturer's EC Declaration of Con-formity and automatically thereby the operating licence.
Foreseeable incorrect use or inappropriate handling include:
Operation in explosion-prone environments
Operation in fire-prone environments
Operation in confined areas
Operation from a vehicle platform that has not been swung out
Operation without the necessary safety redundancies
Operation in existing power supply networks
Refuelling when hot
Refuelling during operation
Spraying with high-pressure cleaners or fire-extinguishing equipment
Safety equipment removal
Incorrect vehicle installation
Non-compliance with maintenance intervals
Failure to measure and test for early damage identifica-tion
Failure to replace wearing parts
Incorrectly performed maintenance or repair work
Defectively performed maintenance or repair work
Status at: January 2013 ESE 604 / 954 DBG DIN 17
Unintended use
2.1.3 Residual risks
The points analysed and evaluated before beginning the design and planning of the ESE 604 / 854 (ES) ( FS) DBG DIN generator were the residual risks using a risk analysis tool according to EN 1050.
Structurally unavoidable residual risks during the entire ser-vice life of the ESE 604 / 854 (ES) ( FS) DBG DIN DIN gen-erator include:
Risk of death
Risk of injury
Environmental hazards
Material damage to the generator
Material damage to other property
Limited performance or functionality
You can avoid existing residual risks by observing and fol-lowing these guidelines:
the special warning notices on the generator
the general safety instructions given in these operating instructions
the specific warnings given in these operating instruc-tions
The specific standing instructions (the relevant opera-tional conditions) issued by fire-brigades, civil defence and other relief organisations
Risk of death to persons at the generator can be caused by:
Incorrect use
Inappropriate handling
Missing protective equipment
Defective or damaged electrical components
Fuel vapours
Engine exhaust gases
Too large a distribution network configuration
Risk of injury to persons at the generator can be caused by:
Inappropriate handling
Risk of death
Risk of injury
18 ESE 604 / 954 DBG DIN Status at: January 2013
Transport
Hot components
Recoiling starter rope on the engine
Environmental hazards involving the generator may be caused by:
Inappropriate handling
Operating fluids (fuel, lubricants, engine oil, etc.)
Exhaust gas emission
Noise emission
Fire hazard
Leaking battery acid
Material damage to the generator can occur through:
Inappropriate handling
Overloading
Overheating
Too low/high oil level of the engine
Non-compliance with the operating and maintenance specifications
Unsuitable operating fluids
Unsuitable hoisting gear
Material damage to other equipment in the operating area of the generator can be caused by:
Inappropriate handling
An overvoltage or an undervoltage
Incorrect installation in a vehicle
The generator's performance or functionality can be limited by:
Inappropriate handling
Inappropriate maintenance or repair work
Unsuitable operating fluids
An installation altitude greater than 100 metres above sea level
An ambient temperature exceeding 25°C
Too large a distribution network configuration
Environmental hazards
Material damage to the generator
Material damage to other property
Welding generator's performance or
functionality limitations
Status at: January 2013 ESE 604 / 954 DBG DIN 19
2.2 Operating personnel – qualifications and obligations
Only appropriately authorised personnel may work with or on the generator.
The authorised operating personnel must:
be at least 18 years old.
be trained in first aid and able to provide it.
be familiar with the accident prevention regulations and generator safety instructions and be able to apply them.
have read the chapter “General Safety Regulations”.
has understand the content of the chapter “General Safe-ty Regulations”.
be able to use and implement the content of the chapter “General Safety Regulations” in practice.
be trained and instructed according to the rules of con-duct in the event of a malfunction occurring.
have the physical and mental abilities to carry out his responsibilities, tasks, and activities on the generator.
be trained and instructed in his responsibilities, tasks and activities on the alternator.
have understood the technical documentation concerning his responsibilities, tasks and activities on the alternator and be able to implement these in practice.
2.3 Personal protective equipment
This personal protection equipment must be worn during all activities at the generator described in these operating in-structions:
hearing protection
protective gloves
hard hat
protective shoes
fireproof protective clothing (in areas where the danger of fire is high)
20 ESE 604 / 954 DBG DIN Status at: January 2013
2.4 Danger zones and work areas
The danger zones and work places (work areas) around the generator are determined by the activities to be undertaken within the individual life cycles:
Life cycle Activity Danger zone Work area
Transport in the vehicle Radius of 1.0 m none
by the operating per-sonnel
Radius of 1.0 m
Operation Setting up
Operating Radius of 5.0 m
Refuelling Radius of 2.0 m
Service and maintenance
Cleaning Radius of 1.0 m
Shutting down
Maintenance
Table 2.1: Danger zones and work areas on the generator
Status at: January 2013 ESE 604 / 954 DBG DIN 21
2.5 Signs on the generator
These signs must be fitted on the generator and be kept in a clearly legible condition:
Figure 2-1: Signs on the generator
10 Abridged operating instructions (inside cover)
70 Nameplate
20 Reference note - read operating in-structions
80 Reference note - three-way valve
30 Reference note - no naked flames 90 Maintenance note
40 Fuel note 100 Note on the hot surface
50 Note on speed set at the works 110 Motor model plate
60 Note on power network 120 Potential equalisation screw (for an FI earthing connection)
22 ESE 604 / 954 DBG DIN Status at: January 2013
Sign Name
Short operating in-structions (inner side
of the flap)
Read the operating manual
Reference note - no naked flames
Fuel note
Note on engine speed set at the works
Note
Line extension
Nameplate
External refuelling
Reference note - en-gine maintenance
Hot surfaces
Motor model plate
Potential equalization (earthing for FI)
Table 2.2: Signs on the generator
Status at: January 2013 ESE 604 / 954 DBG DIN 23
2.6 General safety instructions
The generator's construction may not be modified in any way.
The motor's nominal rpm has been set in the factory and may not be changed.
All protective covers must be at hand and functional.
All signs on the generator must be in place and be in a clear-ly legible condition.
The operational reliability and functionality must be checked before and after each use/operation.
The generator is only be used outdoors and with sufficient ventilation.
Do not use open flames, lights, or spark-inducing devices in the generator’s danger area.
Protect the generator against moisture and precipitation (rain, snow) during operation.
Protect the generator against dirt and foreign matter during operation.
The authorised personnel are responsible for the operational reliability of the generator.
The authorised personnel are responsible for safeguarding the generator against unauthorised operation.
The authorised personnel are obligated to observe the appli-cable accident prevention regulations.
The authorised personnel are obligated to obey the safety and work instructions of superiors and/or safety officers.
The authorised personnel are obligated to wear personal protective equipment.
Only authorised personnel may remain in the generator's danger zone.
Smoking is absolutely prohibited in the generator's danger zone.
24 ESE 604 / 954 DBG DIN Status at: January 2013
Open flames and light are prohibited in the generator's dan-ger zone.
Consuming alcohol, drugs, medicines, or other conscious-ness-expanding and/or changing substances is prohibited.
The authorised personnel must be familiar with the generator components and their function and know how to use them.
The generator is only be transported after it has cooled down.
The generator may only be transported in a vehicle after be-ing fastened in place correctly (on the transport device).
The generator is only be lifted by the carrying handles pro-vided.
The generator is to be carried by at least one person per carrying handle.
The generator is only be set up on sufficiently firm ground.
The generator may only be set up on even ground.
The electrical safety must be checked before each start-up.
Do not cover the equipment during use.
Do not obstruct or block the air supply.
Do not use starting aids.
Devices must not be connected during start-up.
Only tested and authorised cables may be used for the pow-er network.
It is prohibited to establish a connection between existing neutral conductors, potential equalisation conductors and/or equipment components (safety-separated circuit).
The entire drawn output must not exceed the maximum nom-inal output of the generator.
Transport
Setting up
Generating electricity
Status at: January 2013 ESE 604 / 954 DBG DIN 25
Do not operate the generator without a sound damper.
It is prohibited to operate the generator without air filters and with an opened air filter cover.
It is prohibited to refill the generator's fuel tank during opera-tion.
It is prohibited to refill the fuel tank on the generator when it is still hot.
Use filling aids for refuelling.
It is prohibited to clean the generator during operation.
It is prohibited to clean the generator when it is still hot.
Refuelling
Cleaning
26 ESE 604 / 954 DBG DIN Status at: January 2013
Operating personnel may only carry out the maintenance or repair work described in these operating instructions.
All other maintenance or repair tasks may only be carried out by specially trained and authorised specialists.
Always remove the ignition key and the spark plug sockets before beginning maintenance and/or repair work.
The maintenance intervals specified in these operating in-structions must be observed.
It is prohibited to service the generator during operation.
It is prohibited to service the generator when it is still hot.
The generator should be put out of service if it is not required for more than 30 days.
Store the generator in a dry and locked room.
Use a petrol additive to prevent resinous residues in the fuel system.
One copy of these operating instructions must always be kept in the generator’s manual compartment.
The operating instructions and the maintenance instructions for the engine (Briggs & Stratton Corporation) are integral parts of this instruction manual.
The packaging material must be recycled according to the environmental protection regulations applicable at the place of use.
The workplace must be protected against contamination by leaking operating fluids.
Used or leftover fuels and lubricants must be recycled ac-cording to the environmental regulations applicable at the place of use.
Maintenance and repair work
Decommissioning
Documentation
Environmental protection
Status at: January 2013 ESE 604 / 954 DBG DIN 27
Notes
28 ESE 604 / 954 DBG DIN Status at: January 2013
3 Description of the ESE 604 / 954 DBG DIN generator
The components and functionality of the generator are de-scribed in this section.
3.1 Components of the ESE 604 / 954 DBG DIN generator
The generator components are distributed on all four sides.
Fig. 3-1: Views of the generator
1 Generator side 3 Engine side
2 Exhaust gas side 4 Control side
Status at: January 2013 ESE 604 / 954 DBG DIN 29
3.1.1 Components of the operating and generator side
Fig. 3-2: Components of the operating and generator side
1 Alternator 5 Cover flaps
2 Oil filter 6 Cold start (choke), engine
3 Fuel filter 7 Spark plug connector
4 3-way fuel valve (optional)
30 ESE 604 / 954 DBG DIN Status at: January 2013
3.1.2 Exhaust and engine side components
Figure 3-3: Exhaust and engine side components
1 Air filter 6 Spark plug connector
2 Carrying handle 7 Oil filling screw
3 Starter grip for the engine 8 Exhaust
4 Potential equalization (earthing for FI) 9 Tank
5 Oil drain screw 10 Fixing points according to DIN14685
Status at: January 2013 ESE 604 / 954 DBG DIN 31
3.1.3 Control panel components
Fig. 3-4: Control panel components
1 Frame for fuse boxes 4 Multi-functional display
2 Fuses 5 CEE 400V/16A according to DIN49462
3 Insulation monitoring test socket
(valid for devices up to year of con-struction 12/2015)
6 Schuko 230V according to DIN49442
32 ESE 604 / 954 DBG DIN Status at: January 2013
3.1.4 Accessory components
3.1.4.1 Standard accessories
Figure 3-5: Components of the standard accessories
1 Spark plug wrench 4 Test probes
(valid for devices up to year of con-struction 12/2015)
2 User information (operating instruc-tions for the engine, as well as these
operating instructions)
5 Spark plugs (2x)
3 Testing cable
(valid for devices up to year of con-struction 12/2015)
Status at: January 2013 ESE 604 / 954 DBG DIN 33
3.1.4.2 Special accessories
Fig. 3-6: Components of the special accessories
1 Fuelling device 3 Exhaust hose DN 50 – 1500 mm
2 20 litre standard container according to DIN 14572
3.2 Function and mode of operation
The synchronous generator is firmly coupled to the drive engine. The assembly is installed in a stable frame and equipped with a flexible, low-vibration suspension.
Splash-proof earthed power and CEE sockets with a nominal voltage of 230 and/or 400 V/50 Hz supply the power.
An integrated voltage regulator controls the voltage of the generator in the nominal speed range of the generator.
The generator is designed for mobile operation with one or more electrical consumers (safety-separated circuit accord-ing to VDE 100, Part 551). The protective conductor of the ground contact socket assumes the function of the potential equalisation line.
34 ESE 604 / 954 DBG DIN Status at: January 2013
Notes
Status at: January 2013 ESE 604 / 954 DBG DIN 35
4 Operating the ESE 604 / 954 DBG DIN generator
The operation of the generator is described in this section.
4.1 Transporting the generator
Proceed as follows to transport the generator.
The following requirements must be met:
The generator must be turned off
The generator must have cooled down.
The fuel valve is in the “OFF“ position
The fuelling device (a special accessory see 3.1.4.2) is disconnected
Exhaust hose (a special accessory see 3.1.4.2) is not attached
At least one person per carrying handle
WARNING!
A slipping or falling device can crush hands or feet.
Take the weight of about 120 kg into account.
Carry the alternator using at least one person per carry-ing handle.
Only lift the alternator by the carrying handles.
Lift / lower the alternator evenly.
Walk slowly.
1. Unfold carrying handles.
2. Lift generator evenly.
3. Carry the generator to the work site.
4. Lower generator evenly.
5. Fold carrying handles.
The generator has been carried to its work site.
4.2 Setting up the generator
Proceed as follows to set up the generator.
Requirements
Carrying the generator
36 ESE 604 / 954 DBG DIN Status at: January 2013
The following requirements must be met:
An even and firm substratum outdoors
There are no inflammable materials at the operating site
There are no explosive materials at the operating site
WARNING!
Leaking engine oil and petrol can contaminate the soil and groundwater.
Prevent leaking of engine oil and petrol.
Set up the generator as follows:
1. Prepare the work site.
2. Transport the generator to the work site.
3. Attach the exhaust hose if necessary (a special accesso-ry see 3.1.4.2)
The generator is set up and ready for use.
4.3 Refuelling the generator
Proceed as follows to refuel the generator.
The following requirements must be met:
The generator must be switched off (see 4.5).
The device must be cooled down.
Adequate ventilation must always be available
Appliances switched off or disconnected
WARNING!
Leaking engine oil and petrol can burn or explode!
Requirements
Setting up the generator
Requirements
Status at: January 2013 ESE 604 / 954 DBG DIN 37
Prevent leaking of engine oil and petrol.
Generator is switched off.
Generator has cooled down.
Avoid open flames and sparks.
WARNING!
Leaking engine oil can contaminate the soil and groundwater.
Do not fill the tank completely.
Use a filling aid.
WARNING!
Using the wrong fuel will destroy the engine.
Only refuel with lead-free regular grade petrol RON 91.
Refuel the generator as follows:
1. Set the fuel cock to “closed“ (Figure 5-10-(1)).
2. Unscrew tank cover.
3. Insert filler aid into the filler neck.
4. Add petrol.
5. Remove filler aid.
6. Screw on tank cover
The device is refuelled.
4.4 Starting the generator
Proceed as follows to start the generator.
Refuelling the device
38 ESE 604 / 954 DBG DIN Status at: January 2013
The following requirements must be met:
Electrical safety check (see 6.3)
Fuel tank has been filled (see 4.3)
A possibly connected fuelling device (special accessory)
sufficient oil level (fill with engine oil before initial use, see the engine operating and maintenance instructions)
ventilation must be adequate.
Fit push-on exhaust gas pipe (special accessory) if needed
a connected and operational starter battery
Appliances switched off or disconnected
WARNING!
Operating fluids can burn or explode.
Prevent leaking of engine oil and petrol.
Do not use starting aids.
Avoid open flames and sparks.
WARNING!
Exhaust gases can cause fatal asphyxiation.
Provide for sufficient ventilation.
Use an exhaust gas pipe.
Only operate the generator outdoors.
WARNING!
Hot parts can ignite flammable and explosive materials.
Avoid flammable materials at the operating site.
Avoid explosive materials at the operating site.
WARNING!
Heat or moisture destroys the device.
Avoid overheating (sufficient ventilation).
Avoid moisture.
Start the engine as follows:
Requirements
Starting the motor
Status at: January 2013 ESE 604 / 954 DBG DIN 39
Figure 4-1: Started by hand:
1. Pull on the choke (Figure 4-1-(1)) (completely for a cold engine / appropriately less for a warm engine) and hold firmly.
2. Place the red engine switch (Figure 4-1-(2)) in Pos. “I“.
3. Advance engine at the hand grip of the reversing starter.
Support oneself with one hand on the device grip in order to simplify advancing the engine.
The motor starts.
4. Move the choke slowly back into its start position.
The engine has started.
The electrical devices can be connected and/or hooked up after a warming-up phase of about one minute.
HAND START
NOTE
NOTE
40 ESE 604 / 954 DBG DIN Status at: January 2013
Figure 4-2: Electrical start
1. Pull on the choke (Figure 4-1-(1)) (completely for a cold engine / appropriately less for a warm engine) and hold firmly.
2. Bring the key-operated switch (Figure 4-2-(1)) into pos. Start (Figure 4-2-(4)).
Only activate the starter briefly (max. 5-10 seconds). Never start or run the engine with the battery disconnected.
The motor starts.
3. Bring the key-operated switch into the pos. Operation (Figure 4-2-(3)).
4. Move the choke slowly back into its start position.
The engine has started.
The electrical devices can be connected and/or hooked up after a warming-up phase of about one minute.
(Type No: 151022 / 151024)
See Chapter 5.4 Remote start device
WARNING!
ELECTRICAL START
Note
NOTE
When the special equipment Remote Start is
installed
Status at: January 2013 ESE 604 / 954 DBG DIN 41
Devices with a remote start device are fitted with an automatic choke. You do not need to use the manual choke (on the engine).
4.5 Switching the generator off
Proceed as follows to shut down the generator.
WARNING!
Hot parts can ignite flammable and explosive materials.
Avoid flammable materials at the operating site.
Avoid explosive materials at the operating site.
Allow the generator to cool down.
The device is switched off as follows:
1. Switch off or disconnect devices.
2. Continue to run the engine for about two minutes.
3. Place the red engine switch (Figure 4-1-(2)) in pos. “0“.
1. Switch off or disconnect devices.
2. Continue to run the engine for about two minutes.
3. Place the key-operated switch (Figure 4-2-(1)) in pos. STOP (Figure 4-2-(2)).
See Chapter 5.4 Remote start device
Switching the device off
Started by hand:
Electrical start
Special equipment Remote Start
42 ESE 604 / 954 DBG DIN Status at: January 2013
4.6 Connecting up to consumers
Proceed as follows to connect appliances to the generator.
The following requirements must be met:
generator started
protective earthing conductor tested
device switched off
WARNING!
Electric shocks cause injury or death.
Do not earth the generator.
Do not connect protective conductor to an existing po-tential equalisation line.
Do not connect the generator to an existing electrical grid.
You can connect devices using Schuko or CEE sockets.
Fig. 4-3: Connecting up to consumers
Proceed as follows to connect a device to the control panel:
1. Unscrew covering on the socket .
2. Push the plug into the socket.
The consumer is connected to the generator.
Switch the consumer on as follows:
Requirements
Connecting up to consumers
Connecting up to consumers
Switching the consumer on
Status at: January 2013 ESE 604 / 954 DBG DIN 43
1. Switch consumer on.
Consumer is connected.
Switch the consumer off as follows:
1. Switch consumer off.
Consumer is switched off.
Disconnect a consumer from the control panel as fol-lows:
1. Remove plug.
2. Screw cover onto the socket .
The consumer is disconnected from the generator.
Switching the consumer off
Disconnecting an appliance
44 ESE 604 / 954 DBG DIN Status at: January 2013
4.7 Check the protective conductor (valid for devices up to year of construction 12/2015)
Proceed as follows to check the protective conductor con-nection between the generator and the consumer.
The following requirements must be met:
generator has been started (see 4.4)
device is connected (see 4.6)
device switched off
WARNING!
Electric shocks cause injury or death.
Do not earth the generator.
Do not connect protective conductor to an existing po-tential equalisation line.
Do not connect the generator to an existing electrical grid.
Figure 4-4: Check the protective conductor
1. Insert test cable into socket (Figure 4-4-(2)).
2. Hold a test tip an a metallic, blank location on the device.
The test lamp (Figure 4-4-(1)) on the multifunction display shows the result:
Requirements
Check the protective conductor
Proceed as follows to check the protective
conductor between the consumer and the
generator:
Status at: January 2013 ESE 604 / 954 DBG DIN 45
Test lamp Significance
lights up green
protective conductor is OK
stays off Protective conductor defective / not present
Table 4.1: Protective conductor test lamp
The protective conductor / potential equalization for this device has been checked.
46 ESE 604 / 954 DBG DIN Status at: January 2013
4.8 Monitoring the operating status using the multifunction display
The display is only activated after the generator has been started.
All LEDs light up for about 2 seconds to allow checking as soon as the START-STOP switchis set to the position “ON”. The normal operational lighting is then shown afterwards for about 30 seconds. If the engine is not started within this pe-riod, the E-MCS 4.0 goes into energy saving mode and the display goes dark. To bring the E-MCS 4.0 back into a ready-to-operate condition again, the START-STOP switch must first be turned into the position “OFF”. The display in-tensity depends on the ambient light.
Figure 4-5: Multi-functional display
Displayed (see Figure 4-55-(1)) when the generator has started or is activated for 30 seconds when the START / STOP switch is turned to the “Operate” position.
If the display is red (see Figure 4-55-(16)) whilst the generator is running then the temperature is too high and the generator must be switched off.
(Only active if the special “Warning signal II”, “Firecan” option is fitted!)
Manual start / Electrical start
Electrical start with Remote Start
Operating hours:
Ambient temperature:
Status at: January 2013 ESE 604 / 954 DBG DIN 47
If the display is red (see Figure 4-55-(15)) whilst the generator is running then the oil pressure is too low and the generator switches off automatically or the buzzer sounds, this can be acknowledged using the acknowledgement button. (Buzzer only active for the ordered “Insulation monitoring“, “Firecan“) spe-cial fitting
If the display is red (see Figure 4-55-(14)) whilst the generator is running then the engine temperature is too high and the generator must be switched off.
(Only active if the special “Warning signal II, Firecan” option is fitted!)
If the display is red (see Figure 4-55-(13)) whilst the generator is running then the fuel temperature is too high and the genera-tor must be switched off.
(Only active if the special “Warning signal II”, “Firecan” option is fitted!)
If the display is red (see Figure 4-55-(12)) then the generator’s recharging function is not working. If the display flashes red then the charge voltage of the al-ternator is too high.
If the display lights up red (see Figure 4-55-(9)) or if the buzzer sounds then there is an insulation fault present. (see Chapter 5 Insulation monitoring).
(Only active for an ordered insulation monitoring (standard for DIN)!)
If the display glows green (see Figure 4-55-(10)) during the pro-tective earth lead test (see chapter 4.7 Protective earth lead test), the protective earth leads for the attached devices are OK. If the protective earth conductor function is not available, the display remains blank.
There is no electrical tank sensor for this device. Display is only possible using the optical tank sensor.
Load (P∑) (see Figure 4-6-(7))
For a 1 and 3 phase load the total load on the generator is displayed in steps of 10%. 10 - 80% green, 80 - 100% yellow and 100 - 110% red.
If the “OFF” symbol glows red (see Figure 4-5-(4)) and the buzzer sounds, the EMERGENCY OFF button has been pressed. The buzzer can be acknowledged using the acknowledgement button. (Buzzer only active for the ordered “Insulation monitoring“, “Firecan“) spe-cial fitting
If the display glows green (see Figure 4-5-(8)), the frequency is within the correct range (47.5–52.5 Hz).
Oil pressure:
Engine temperature:
Fuel temperature:
Battery charge check:
Insulation monitoring:
Protective earthing conductor test:
Fuel tank filling level:
Relative load indicator:
EMERGENCY-STOP button:
Frequency:
48 ESE 604 / 954 DBG DIN Status at: January 2013
If the “high” display is red then the frequency is too high. If the “low” display is red then the frequency is too low. The single L1 to L3 phases (see Figure 4-5-(18)) are displayed separately: Voltage (U) (see Figure 4-5-(17)): If the field is green then the voltage is OK. If “high” or “low” is displayed in red then the voltage is too high or too low. Load (P) (see Figure 4-5-(18)): The utilisation will be displayed in 10% steps for 3-phase loads. 10 - 80% green, 80 - 100% yellow and 100 - 110% red. The utilisation will be displayed in 10% steps for 3-phase loads. 10 - 80% green, 80 - 100% yellow and 100 - 110% red.
If the display is red for single phase utilisation (asymmetric load), the load should be distributed evenly over the 3 exist-ing phases.
L1, L2 & L3 phases:
Status at: January 2013 ESE 604 / 954 DBG DIN 49
4.9 Putting the generator out of service
The generator should be put out of service if it is not required for more than 30 days. It is best to use a cloth to cover the generator.
The correct putting out of service procedure is described in the engine’s operating manual and maintenance instructions (Briggs & Stratton Corporation) (Figure 3-5-(2)).
4.10 Disposal
Due to environmental protection considerations the genera-tor, battery, engine oil etc. cannot simply be thrown into the refuse bin. Observe all local laws and regulations concerning correct disposal of such parts and substances. Your author-ised ENDRESS generator dealer is happy to advise you.
Please observe the pertinent environmental protection regu-lations when disposing of the old oil. We recommend bring-ing the oil in a closed container to an old oil collection centre for disposal. Do not throw away used engine oil into the re-fuse bin or pour it onto the ground.
An inappropriately disposed of battery can damage the envi-ronment. Always comply with the local regulations when dis-posing of batteries. Please contact your ENDRESS mainte-nance dealer for a replacement.
NOTE
50 ESE 604 / 954 DBG DIN Status at: January 2013
Notes
Status at: January 2013 ESE 604 / 954 DBG DIN 51
5 Special fittings / using accessories
5.1 FI protection switch
The FI circuit breaker (RCD) is a protective measure against dangerous body currents according to DIN VDE 0100-551.
1. The assembly's earthing connection clamps must be connected to the earthing spike by at least 16mm² of earthing cable (green/yellow). The spike must be driven into the ground. BG Bau recommends an earthing resistance of ≤ 50Ω (see BGI 867).
2. Alternatively, a proper earthing device conforming to VDE 0100-540 can be used (such as the main earth-ing line in buildings).
WARNING!
The generator must be earthed.
In this special case the generator must be earthed! The above-mentioned safety warnings with other wording are not relevant for this special fitting.
1. The effectiveness of this protective measure must be checked at least once a month by an electrical expert or, if suitable measuring and testing devices are available, by an electrotechnically trained person un-der the guidance and supervision of an electrical ex-pert.
2. Additionally, every work day, the user must check the mechanical operation of the release by activating the test button (seeunterhalbFigure 5-1-10)) on the residual current protection device (RCD).
Earthing requirements:
Attention!
52 ESE 604 / 954 DBG DIN Status at: January 2013
Figure 5-1: FI protection switch
1. The generator must be started.
2. Put the protection switch (seeFigure 5-1-(20)) into position 1.
3. Activate the test switch (seeFigure 5-1-(10)) .
The switch position displays the result (seeFigure 5-1-(20)):
Symbol Significance
Position I Switch does not trigger. FI protection switch is defec-tive.
Position 0 Switch triggers. FI protection switch is working proper-ly.
Table 5.1: FI protection switch test
The device has been tested in compliance with DIN VDE 0100-551.
Checking the FI protection switch:
Status at: January 2013 ESE 604 / 954 DBG DIN 53
5.2 Insulation monitoring using E-MCS 4.0
The insulation monitoring option can only be supplied by the factory.
Figure 5-2: Insulation monitoring using E-MCS 3.0
5.2.1 Insulation monitoring without switching off
(Standard for a DIN generator)
The following requirements must be met:
Generator has been started (see Fehler! Verweisquelle konnte nicht gefunden werden.)
1. Unplug the device
2. Press the test button (see Figure 5-2-(1))
The displayed symbol (see Figure 4-55-(9)) indicates the result, the buzzer also sounds for insulation monitoring with this and it can be acknowledged over the acknowl-edgement button (see Figure 5-2-(2)):
Symbol Significance
Yellow Insulation monitoring is OK
stays off Insulation monitoring is defective
Table 5.2: Insulation monitoring without switching off
The insulation monitoring test has been run.
1. The reset button (see Figure 5-2-(1)) must be pressed after the test, so that the unit can be operated again.
Requirements
Testing the insulation monitoring:
54 ESE 604 / 954 DBG DIN Status at: January 2013
1. Plug in the device and switch on.
The displayed symbol (see Figure 4-5-(8)) indicates the re-sult:
Symbol Significance
Yellow Insulation fault (≤ 23 kΩ)
stays off Connected unit is OK
Table 5.3: Insulation monitoring whilst running without switching off
If an insulation fault exists and the unit was previously OK when tested without a device connected (see insula-tion monitoring above), the insulation fault has been caused by the device.
2. The reset button (see Figure 5-2-(1)) must be pressed after switching off and disconnecting the consumer so that the unit can be operated again.
Action Operation
Press once Acknowledge the buzzer
Press twice Reset ISO
5.2.2 Insulation monitoring with switch off
The following requirements must be met:
Generator has been started (see 4.4)
1. Unplug the device
2. The circuit breaker must be in Pos. 1.
3. Press the test button (see Figure 5-2-(2))
The displayed symbol (see Figure 4-5-(8)) and the position of the circuit breaker indicate the result:
Insulation monitoring whilst running:
Function reset/acknowledgement
button:
Requirements
Testing the insulation monitoring:
Status at: January 2013 ESE 604 / 954 DBG DIN 55
Symbol Result Significance
lights up red Circuit breaker jumps to Pos. 0 and
the generator cuts out Insulation monitoring is OK
stays off Circuit breaker stays in Pos. 1 and
the generator continues to run Insulation monitoring is defective
Table 5.4: Insulation monitoring plus switching off
The insulation monitoring test has been run.
4. The circuit breaker must be returned to Pos. 1 after the test has been completed and the generator must be re-started so that it can be used again.
1. Plug in the device and switch on.
The displayed symbol (see Figure 4-5-(8)) and the position of the circuit breaker indicate the result:
Symbol Significance
lights up red Insulation fault (≤ 23 kΩ)
Yellow Insulation fault (≤ 34.5 kΩ)
stays off Connected unit is OK
Table 5.5: Insulation monitoring whilst running without switching off
If an insulation fault exists and the unit was previously OK when tested without a device connected (see above), the insulation fault has been caused by the device.
2. After the device has been switched off and unplugged, the circuit breaker must be returned to Pos. 1, and the generator must be restarted, in order for the device to be operated again.
Insulation monitoring whilst running:
56 ESE 604 / 954 DBG DIN Status at: January 2013
5.3 Speed lowering in idle
Proceed as follows to operate the generator with idle down.
The following requirements must be met:
generator is ready for operation
generator has been started (see 4.4)
Figure 5-3: Switching the idle down on pressure switch
Switch on idle speed reduction as follows:
Press pressure switch (Figure 5-3-(1)) until it engages (LED
lights up green).
Idle down is activated.
The idling speed reduction is active for about 5 minutes after engine start and then lowers the rotational speed of the en-gine, in as far as no load is engaged, to about 1800 rpm. The engine speed will be increased to the nominal speed as soon as a load is switched on. The engine always runs within the nominal speed range if the rocker switch is in the "OFF" posi-tion.
Switch the idle down off as follows:
Press the press switch again (LED goes out).
Idle down is switched off.
Requirements
Switching the idle down on
ATTENTION
Switching idle down off
Status at: January 2013 ESE 604 / 954 DBG DIN 57
5.4 Remote start device
Standard for type no.: 151022 / 151024
Proceed as follows to operate the generator using the re-mote start device.
The following requirements must be met:
generator is ready for operation
WARNING!
Devices with a remote start device are fitted with an auto-matic choke. You do not have to use the manual choke dur-ing an electrical start.
Connect up the remote start device as follows:
Figure 5-4: Connecting up a remote start device
1. Unscrew protective cap on the remote start socket (Figure
5-4-(1)).
2. Insert plug for the remote start operating status / genera-tor connecting cable into the remote start socket and lock in place by turning to the right.
Remote start device is ready for use.
Requirements
Connecting up a remote start device
58 ESE 604 / 954 DBG DIN Status at: January 2013
Disconnect the remote start device as follows:
1. Release the plug by turning to the left and then pull the remote start operating status / generator connecting ca-ble plug out.
2. Screw protective cap onto the remote start socket (Figure
5-4-(1)).
Remote start device is disconnected.
Start the engine manually as follows:
Figure 5-5: Electrical start in combination with remote start
1. The EMERGENCY-OFF button (Figure 5-5-(2)) must not be pressed.
2. Place operating switch (Figure 5-5-(3)) in pos. ON.
3. Press the start knob (Figure 5-5-(1)).
Only activate the starter briefly (max. 5-10 seconds). Never start or run the engine with the battery disconnected.
The motor starts.
4. Release the start knob.
The engine has started.
The electrical devices can be connected and/or hooked up after a warming-up phase of about one minute.
Disconnecting the remote start device
Starting the motor
ELECTRICAL START
NOTE
NOTE
Status at: January 2013 ESE 604 / 954 DBG DIN 59
The device is switched off as follows:
1. Switch off or disconnect devices.
2. Continue to run the engine for about two minutes.
3. Place operating switch (Figure 5-5-(3)) in Pos. OFF.
WARNING!
In an emergency, the generator can be stopped by pressing the “EMERGENCY-OFF switch” (Figure 4-2-(1)). The button is turned to the left or the right to restart the aggregate until the locking is removed again.
We request that you only switch off the device using the EMERGENCY-STOP switch in an emergency. Otherwise always switch off using the START-STOP switch! Switching off using the EMERGENCY-STOP switch only interrupts the ignition so it is still possible for fuel to ignite in the silencer due to residual amounts of fuel in the carburettor.
Switching the device off
Electrical start
Note
60 ESE 604 / 954 DBG DIN Status at: January 2013
5.5 External start device
Proceed as follows to operate the generator using the exter-nal start device.
The following requirements must be met:
generator has been started (see 4.4)
Figure 5-6: Connecting up an external start device
Connect up the external start device as follows:
1. Unscrew cover (Figure 5-6-(2) on the external start socket (Figure 5-6-(1)).
2. Insert plug for the external energy source connecting cable (e.g. starter battery) / external start socket into the external start socket and lock in place by turning to the right.
External start device is ready for use.
The engine can be started using the electrical start.
Disconnect the external start device as follows:
1. Release the plug by turning to the left and then pull the external energy source / external start socket plug out.
2. Screw protective cap for the external start socket back on again.
External start device is disconnected.
Requirements
Connecting up an external start device
Disconnecting the external start device
Status at: January 2013 ESE 604 / 954 DBG DIN 61
5.6 Battery charge retention
Proceed as follows to charge the starter battery for the gen-erator over the battery charge retention device.
The following requirements must be met:
generator is ready for operation
Connect up the battery charge conservation device (charge current socket A DIN 14690) as follows:
Figure 5-7: Connecting up the battery charge retention device
1. Unscrew cover (Figure 5-7-(2)) for socket (Figure 5-7-(1)) for the starter battery charge conservation device.
2. Insert plug for the external energy source (e.g. a battery charging device) / charge retention device socket con-necting cable and lock in place by turning to the right.
The battery charge conservation device is ready to oper-ate.
Disconnect the battery charge conservation device as follows:
1. Release the plug by turning to the left and then pull the plug for the external energy source (e.g. a battery charg-ing device) / charge conservation device socket connect-ing cable out.
2. Screw on protective cap (Figure 5-7-(2)) for charge conser-vation device socket.
Requirements
Connecting up the battery charge conservation
device
62 ESE 604 / 954 DBG DIN Status at: January 2013
The charge conservation device is disconnected
Connect up the battery charge conservation device (charge current socket BEOS) as follows:
Fig. 5-8: Connecting up the battery charge retention device
1. Unscrew cover (Figure 5-7-(2)) for socket (Figure 5-7-(1)) for the starter battery charge conservation device.
2. Insert plug for the external energy source (e.g. a battery charging device) / charge retention device socket con-necting cable and lock in place by turning to the right.
The battery charge conservation device is ready to oper-ate.
Disconnect the battery charge conservation device as follows:
1. Release the plug by turning to the left and then pull the plug for the external energy source (e.g. a battery charg-ing device) / charge conservation device socket connect-ing cable out.
2. Screw on protective cap (Figure 5-7-(2)) for charge conser-vation device socket.
The charge conservation device is disconnected
Connecting up the battery charge conservation
device
Status at: January 2013 ESE 604 / 954 DBG DIN 63
Connect up the battery charge conservation device (MagCode socket) as follows:
Fig. 5-9: Connecting up the battery charge retention device
1. Put plug for the external energy source (e.g. a battery charging device) / charge retention device socket con-necting cable in place.
The battery charge conservation device is ready to oper-ate.
Disconnect the battery charge conservation device as follows:
1. Pull off plug for the external energy source (e.g. a battery charging device) / charge conservation device socket connecting cable.
The charge conservation device is disconnected
Connecting up the battery charge conservation
device
64 ESE 604 / 954 DBG DIN Status at: January 2013
5.7 3-way fuel valve / Refuelling device
Proceed as follows to use the refuelling device with the gen-erator.
These requirements must be fulfilled:
generator is ready for operation
3-way fuel valve
In the course of supplying fuel you can select between the device's own tank and the refuelling device.
Figure 5-10: 3-way fuel valve
Switch position Operation
1 CLOSED
2 OWN TANK
3 EXTERNAL REFUELLING
Table 5.6: Switchingpositions of the 3-way fuel tap
Establish a connection to the fuel supply system as follows:
1. Set the fuel valve to the required fuelling mode.
The fuel supply is established.
WARNING!
Leaking engine oil and petrol can contaminate the soil and groundwater.
Do not fill the canister completely.
Allow the fuelling device to drain off.
Requirements
Status at: January 2013 ESE 604 / 954 DBG DIN 65
WARNING!
Using the wrong fuel will destroy the engine.
Only refuel with lead-free regular grade petrol RON 91.
Figure 5-11: Connect up fuelling device
The canister may stand at a maximum of 0.5 m below the level of fuel pump.
Connect up fuelling device as follows:
1. Pull off cover plugs from quick-action coupling.
2. Place the quick-action coupling (Figure 5-11-(1)) on the ex-ternal fuelling connection (Figure 5-11-(2)) .
3. The quick-action coupling engages.
The fuelling device is attached.
Disconnect fuelling device from the generator by:
1. Pulling back the knurled sleeve on the quick-action cou-pling (Figure 5-11-(1)).
The coupling is released.
Connect up fuelling device
Note
Connect up fuelling device:
Disconnect fuelling device:
66 ESE 604 / 954 DBG DIN Status at: January 2013
2. Pull off quick-action coupling with hose from the con-nector.
3. Insert the cover plugs again on the quick-action coupling.
The fuelling device is disconnected from the generator.
Connect the canister to the fuelling device as follows:
1. Open sealing cap on the canister.
2. Introduce hose.
3. Engage catch on the fuelling device.
The canister is attached.
Change an empty canister during operation as follows:
1. Place the full canister next to the empty canister.
2. Open sealing cap on the full canister.
3. Set the fuel cock to the internal tank (Figure 5-10-(2)).
The engine is supplied with fuel over its own tank.
4. Loosen the fuelling device latch on the canister.
5. Remove hose.
6. Introduce hose into the full canister.
7. Engage catch on the fuelling device.
The canister is attached.
8. Set the fuel cock to "external fuelling“ (Figure 5-10-(3)).
The empty canister is exchanged.
Connect up canister
Changing the canister during operation
Status at: January 2013 ESE 604 / 954 DBG DIN 67
5.8 Exhaust hose
Proceed as follows to use the exhaust hose with the genera-tor.
The following requirements must be met:
Generator is ready for operation
WARNING!
Exhaust gases can cause fatal asphyxiation.
Provide for sufficient ventilation.
Use an exhaust gas hose.
Only operate the generator outdoors.
Fig. 5-12 Connecting the exhaust hose
Connect up the exhaust hose as follows:
1. Push the exhaust hose’s grip with the larger opening onto the muffler’s connection.
2. Turn the exhaust hose to the right to lock it in place.
Exhaust hose is now plugged in.
Requirements
Connecting up the exhaust hose
68 ESE 604 / 954 DBG DIN Status at: January 2013
Disconnect the exhaust hose from the generator by:
1. Turn the exhaust hose grip to the left.
2. Pull the exhaust hose off the muffler’s exhaust hose con-nection.
Exhaust hose is now disconnected.
Disconnecting the exhaust hose
Status at: January 2013 ESE 604 / 954 DBG DIN 69
6 Servicing and maintaining the ESE 604 / 854 DBG DIN generator
Generator maintenance is described in this section.
Only personnel from the manufacturer may carry out mainte-nance or repair work not described in this section.
6.1 Maintenance plan
The maintenance work specified in this summary must be carried out after the indicated time intervals.
Maintenance work Time interval in operating hours [h]
after 8 h every 8 h /
daily
every 25 h /
annual-ly
every 50 h /
annual-ly
every 100 h / annual-
ly
annual-ly
Checking the electrical safety before each start-up
Checking the oil X
Changing the oil X (X)1)
Change oil filter X
Cleaning the air filter (X)2)
Clean area around mufflers, linkages, and springs
X
Exchange spark plugs X
Change the fuel filter X
Check fit of screws, nuts, and bolts
X
Check condition and tightness of the fuel hoses and connec-
tions. X
Table 6.1: Generator maintenance plan
1) Every 25 hours when operating under a heavy load or at high ambient temperatures.
2) Clean more frequently when used in a dusty environment or in the presence of foreign particles in the air or for longer use in high, dry grass.
70 ESE 604 / 954 DBG DIN Status at: January 2013
6.2 Maintenance work
Only authorised personnel are allowed to carry out mainte-nance tasks.
Perform all work in the maintenance plan according to the information in the engine's operating and maintenance man-ual (Figure 3-5-(2)). These operating and maintenance instruc-tions of the engine manufacturer are an integral component of these operating instructions.
6.2.1 Motor oil
WARNING!
Leaking engine oil can contaminate soil and groundwa-ter.
Use an oil collection container.
Recycle used motor oil
WARNING!
Engine oil can be hot — risk of burns.
Allow motor to cool
The following requirements must be met:
The engine should ideally be slightly warm (allow a cold engine to run for 5 min., then stop it and allow it to cool for 2 min.).
Figure 6-1: Oil dipstick
Requirements
Status at: January 2013 ESE 604 / 954 DBG DIN 71
Check the oil level as follows:
1. Pull out the dipstick (Figure 6-1-(2)) and wipe it off with a clean cloth.
2. Reinsert the dipstick and take it out again. Drain off some of the oil if the level is above the upper mark and refill with oil if the level is under the lower mark (see below).
The oil level has been checked.
Pour in oil as follows:
1. Remove oil screw plug (Figure 6-1-(1)). Pull out the dipstick for easier filling ((Figure 6-1-(2)).
2. Fill with oil using a filling aid.
3. Check oil level and add oil if necessary.
The engine has been refilled with oil.
Figure 6-2: Changing the oil
Checking the oil
Refilling with oil
72 ESE 604 / 954 DBG DIN Status at: January 2013
1. Remove the oil filling screw (Figure 6-1-(1)).
2. Prepare the oil collecting tray.
3. Unscrew oil drainage screw (Figure 6-2-(1)) carefully and wait until oil has completely run off into the collection container.
4. Screw on oil drainage screw (Figure 6-2-(1)) again.
5. Then refill with fresh oil.
Engine oil has been drained.
WARNING!
The oil escapes immediately after unscrewing the oil drain screw.
When changing the oil filter (Figure 6-2-(2)) , proceed as de-scribed in the engine manual.
Changing the oil
Change oil filter
Status at: January 2013 ESE 604 / 954 DBG DIN 73
6.2.2 Replacing the starter battery
1. Unscrew the battery holder (Figure 6-3-(1)).
2. Remove the battery (Figure 6-3-(2)) from the battery com-partment.
3. Unscrew the battery cable. Push the protective terminal caps back for this purpose and loosen the screws. Al-ways disconnect the cable from the NEGATIVE terminal first and then disconnect the cable from the POSITIVE terminal.
Battery is disconnected.
Figure 6-3: Replacing the battery
4. Prepare a new battery.
5. The battery cables must first be screwed onto the POSI-TIVE terminal, then onto the NEGATIVE-terminal and then put on the terminal caps.
6. Put the battery back into the battery compartment.
7. Put the battery holder (Figure 6-3-(1)) back on.
The battery has been replaced.
WARNING!
A highly explosive electrolytic gas mixture develops from gassing when charging batteries.
Flames, sparks, an open light and smoking are prohibit-ed.
Avoid sparks when handling cables and electrical devic-es, as well as electrostatic discharge.
Avoid short-circuits.
CAUTION!
74 ESE 604 / 954 DBG DIN Status at: January 2013
The Endress battery is maintenance-free throughout its entire service life.
Never open the battery — this may destroy it.
6.2.3 Replacing fuses
Replacing fuses (only for the special accessory external start socket, socket, charging retention and/or remote start de-vice)
1. Open the fuse holder.
2. Replace the fuse.
3. Close the fuse holder
The fuse has been replaced.
Fig. 6-4: Replacing a fuse
Fuse type Amperes needed for
2 20 Remote start device
2 15 Charging retention socket
1 150 External start (Nato) socket
Table 6.2: Location of the fuses
Status at: January 2013 ESE 604 / 954 DBG DIN 75
6.3 Checking the electrical safety
Only specifically authorised personnel may check the electri-cal reliability.
The electrical reliability must be checked in accordance with the applicable VDE regulations, EN and DIN standards and especially the current version of the BGV A3 accident pre-vention regulations.
76 ESE 604 / 954 DBG DIN Status at: January 2013
7 Troubleshooting
This section describes problems during operation that au-thorized personnel can remove.
Each occurring problem is described with its possible cause and the respective corrective measure.
The authorised personnel must immediately shut down the generator and inform the responsible and authorised service personnel if a problem cannot be solved with the aid of the following table.
Malfunction Possible cause Correction
No or insufficient voltage available during idling.
The rotational speed of the engine was adjusted after-
wards.
Call service staff.
The electronic controller has been altered.
Call service staff.
The electronic controller is defective.
Call service staff.
Strong voltage fluctuations occur.
The engine runs irregularly. Call service staff.
The speed control works er-ratically or insufficiently.
Call service staff.
The engine does not start.
The engine is being operated incorrectly.
Follow the engine operating manual instructions.
Maintenance of the engine was inadequate.
Follow the engine mainte-nance instructions.
The oil level monitor actuates. Check oil level and refill if necessary.
Oil pressure switch plug is loose.
Check fit of the oil pressure plug.
Too little fuel in the tank. Refuel
The fuel filter is clogged. Replace the fuel filter.
Bad fuel in the tank. Call service staff.
The ignition cable does not have any connection to the
spark plug.
Attach ignition cable to the spark plug.
The choke is not activated in a cold condition.
Actuate choke.
The EMERGENCY-STOP button is pressed and locked
in place.
Unlock the EMERGENCY-STOP button.
Status at: January 2013 ESE 604 / 954 DBG DIN 77
Malfunction Possible cause Correction
The battery connecting cables are unclamped.
Clamp or screw on the battery connecting cables.
Starter battery has no power. Battery is discharged. Charge battery.
Battery is defective. Exchange battery.
Battery terminals are oxi-dized.
Clean battery terminals and if necessary apply terminal
grease.
Starter battery is not being charged.
Alternator / charge regulator defective.
Call service staff.
The engine does not rotate. Engine defective. Call service staff.
The engine smokes. Too much oil in the engine. Drain excess oil.
Paper element of the air filter is dirty or oil-soaked.
Clean paper element or re-place if necessary.
Foam element of the air filter is dirty or dry.
Clean foam element and if necessary moisten.
The engine turns briefly and then shuts down.
Too little fuel in the tank. Refuel
Ventilation holes on tank cov-er are clogged.
Clean ventilation holes.
The oil level is too low. Add oil.
The fuel filter is clogged. Replace the fuel filter.
The engine splutters. The 20 litre standard contain-er is empty.
Change the canister
The refuelling device’s sieve is blocked.
Clean the sieve.
Carburettor/fuel filter/tank are covered with resin.
Call service staff.
The power output is insuffi-cient.
The electronic controller has been altered.
Call service staff.
The electronic controller is defective.
Call service staff.
Maintenance of the engine was inadequate.
Follow the engine mainte-nance instructions.
Too much power is drawn. Reduce power draw.
The generator runs jerkily. The generator is loaded be-yond the nominal output.
Reduce power draw.
The red lamp on the load me-ter lit up.
Too much power is being tak-en off / the load is being taken
off on one one side.
3~: reduce power take-off / 1~: Distribute the load evenly
The oil pressure is too low. Too little engine oil in the en-gine.
Refill engine oil.
The protective conductor test lamp does not light up.
The test cable is not inserted properly.
Insert the test cable properly.
78 ESE 604 / 954 DBG DIN Status at: January 2013
Malfunction Possible cause Correction
The test tip is not touching a metallic blank location on the
device.
Hold the test tip on a metallic blank location
Test lamp is defective Call service staff.
The protective conductor is defective.
Disconnect the device from the generator.
The protective conductor is missing.
Select the device with a pro-tective earth.
Faults on the special equipment
The engine does not start in remote start mode.
The remote start equipment connecting plug is not insert-
ed properly.
Insert the remote start equip-ment connecting plug correct-
ly.
The automatic choke lifting magnet is defective.
Call service staff.
The remote start equipment fuse is defective.
Replace the fuse.
The engine does not start in external start mode.
The external start equipment plug is not inserted properly.
Insert the external start equipment plug correctly.
The high performance exter-nal start fuse is defective.
Replace the fuse.
The battery is not charging in charge retention mode.
The charge retention plug is not inserted properly.
Insert the charge retention plug correctly.
The charge retention fuse is defective.
Replace the fuse.
Reduce idle speed does not work.
Rocker switch is in the OFF position.
Set the rocker switch to the ON position.
The engine does not run for 5 minutes.
Wait for the minimum running time since an engine start.
There is a load / electrical device switched in.
Switch off load / electrical device.
The lifting magnet for speed lowering in idle is defective.
Call service staff.
Table 7.1: Problems arising during generator operation
Status at: January 2013 ESE 604 / 954 DBG DIN 79
Notes
80 ESE 604 / 954 DBG DIN Status at: January 2013
8 Technical specifications
The technical specifications concerning use of the generator are described in this section.
Fig. 8-1: Generator dimensions
Status at: January 2013 ESE 604 / 954 DBG DIN 81
Name Value Unit
ESE 604 DBG (ES) (FS) DIN
ESE 954 DBG (ES) (FS) DIN
Nominal output 6 8 [kVA]
Nominal output factor 0.8 0.8 [cosφ]
Nominal frequency 50 50 [Hz]
Nominal speed 3000 3000 [min-1]
Nominal voltage 3~ 400 400 [V]
Nominal voltage 1~ 230 230 [V]
Rated current 3~ 8.7 12.3 [A]
Rated current 1~ 18.0 21.7 [A]
Voltage tolerance (idling – nominal output)
± 1 ± 1 [%]
Weight (ready for use) 117 114 [kg]
Tank capacity (lead-free normal ROZ91 fuel)
8.5 8.5 [l]
Length 700 700 [mm]
Width 440 440 [mm]
Height 580 580 [mm]
Sound power level LPA at 7 m 72 72 [db (A)]
Sound pressure at the work place (1.6m above the machine 1m
away) *
89 89 [db (C)]
Sound power level LWA * 97 97 [db (A)]
Protection Class IP 54 IP 54
Table 8.1: Generator technical data
* measured according to ISO 3744 (Part 10)
Technical specifications
82 ESE 604 / 954 DBG DIN Status at: January 2013
Name Value Unit
Setting up height above sea level
< 100 [m]
Temperature < 25 [°C]
Relative air humidity < 30 [%]
Table 8.2: Ambient conditions for the generator
Power reduction for each addi-tional
Unit
1 % 100 [m]
4 % 10 [°C]
Table 8.3: Generator power reduction dependent on ambient conditions
Line max. line length Unit
HO 7 RN-F (NSH öu) 1.5 mm2 60 [m]
HO 7 RN-F (NSH öu) 2.5 mm2 100 [m]
Table 8.4: Maximum line length of the distribution network as a function of
the cable cross-section
The general limitation of 100 m for the overall length was selected in the interest of safe handling during practical use. Larger dimensioning of the distribution network is only to be undertaken by a qualified electrician or trained personnel.
Ambient conditions
Reduced power
Distribution network
Status at: January 2013 ESE 604 / 954 DBG DIN 83
Notes
84 ESE 604 / 954 DBG DIN Status at: January 2013
9 Replacement parts
The replacement parts needed to run the generator are de-scribed in this section.
The generator is divided into these component groups:
Frame with covers, tank and engine
Generator and electronics
Standard accessories
Special accessories
Special equipment
9.1 Frame with covers, tank and engine
Figure 9-1: Operating and alternator side replacement parts
Status at: January 2013 ESE 604 / 954 DBG DIN 85
Fig. 9-2: Engine and exhaust side replacement parts
Item Part number Quantity Article name
10 E503828/10 1 Frame complete, yellow
20 E502064/90 4 Carrying handle, black
E130579 4 Inset handle made of soft PVC
E133316 4 Plastic end cap for pipe, 25×2
E130186 4 Polyamide expansion rivets
E130692 4 12.8-18-3 spacer sleeve
E133023 4 M12 x 45 cylindrical screw
E130350 4 Hexagon nut M 12
30 E131296 4 Vibration dampers
40 E503877/99 1 Refuelling bracket (for a three-way valve)
50 E503868/00 1 Heat protection plate - middle
60 E503869/00 1 Smoke deflector
70 E503863/10 1 Yellow hood (alternator side)
E503864/10 1 Hood with a yellow panel (engine side)
80 E502082/10 1 Hoods with a yellow reinforcing plate
86 ESE 604 / 954 DBG DIN Status at: January 2013
Item Part number Quantity Article name
90 E100641 4 Screw-on hinge, 1056-U6
100 E130471 1 Tool pouch
110 E133415 1 Engine Vanguard.16HP/ES Cooler clean
(for 854 and 604)
120 E130563 1 M8 wingnut
E131063 1 Earth strap in copper
130 E503873/00 1 Engine heat conduction plate
140 E503882/92 1 Silencer elbow
150 E131975 1 Silencer
160 E503871/90 1 Heat protection grid, black
170 E503841/10 1 Yellow tank
Table 9.1: Replacement parts for covers
Status at: January 2013 ESE 604 / 954 DBG DIN 87
9.2 Generator and electronics
Fig. 9-3: Replacement parts Generator and electronics
Item Part number Quanti-ty
Article name
E130959 1 Gen syn. 7 kVA IP 54 50Hz (for ESE 604)
E130960 1 Gen syn. 9 kVA IP 54 50Hz (for ESE 854)
163040 1 Battery, 12V – 18h
200 E130422 1 Hinged window No. 40980
E100091 1 Mounting rail TS 35/7.5 (0.21 m)
E503858/10 2 Terminal strip holder yellow
E130177 3 Circuit breaker 2B.16, 2-pin
E100541 1 Circuit breaker 4B.16, 4-pin 415V
210 1 Alternator regulator
220 E130760 1 Oil monitoring 2-cyl.B&S
230 E100076 1 6-pin motor terminal board
240 E130442 1 Telephone socket 16A, 4-mm
88 ESE 604 / 954 DBG DIN Status at: January 2013
Item Part number Quanti-ty
Article name
(valid for devices up to year of construction 12/2015)
250 162314 1 Multi-functional display with a circuit board and con-necting cable
260 E130424 1 CEE panel mounting socket
270 E131799 1 EFXY3R2 interference elimination filter
280 E133007 3 Schuko attachment socket
Table 9.2: Replacement parts for an engine with an exhaust and fuel sys-
tem
* When placing an order, please also enter the serial number on the model plate.
** When placing an order, please also enter the design vari-ant.
Status at: January 2013 ESE 604 / 954 DBG DIN 89
9.3 Fuses
Only for the devices remote start, battery charge retention or external start.
Figure 9-4: Replacement parts for fuses
Item Part number Quantity Article name
800 E132672 1 Flat fuse holder
E132680 1 Flat fuse insert 20 A, DIN 72581 Part 3
E132735 1 Flat fuse insert 15 A, DIN 72581 Part 3
810 E133255 1 Fuse holder for a high performance fuse
E130915 1 150 A high performance fuse
Table 9.3: Replacement parts for fuses
90 ESE 604 / 954 DBG DIN Status at: January 2013
9.4 Accessories and markings
Fig. 9-5: Replacement parts accessories
Item Part number Quantity Article name
900 E130472 2 Champion 12YC spark plugs (no other type may be used)
910 E130545 1 Test probes (valid for devices up to year of con-struction 12/2015)
920 E130446 1 100 cm measuring line
(valid for devices up to year of construction 12/2015)
930 1 Engine operating manual B&S
940 E130534 1 Spark plug wrench
1000 E100592 1 Fuelling device (special accessory)
1010 E100593 1 20 litre canister, Nato standard (special accesso-ry)
1020 E130473 1 DN 50 exhaust hose according to DIN 14572
Status at: January 2013 ESE 604 / 954 DBG DIN 91
Item Part number Quantity Article name
(special accessory)
Table 9.4: Replacement parts for accessories / special accessories
Fig. 9-6: Replacement parts forspecial accessories